Process for reducing non-uniformities in the density of sintered materials

1. A pre-sintering process for reducing non-uniformities in the density of a sintered material, the pre-sintering process comprising:

(a) providing a mixture of

(i) a first sinterable material containing a contaminant the presence of which during sintering of said first sinterable material results in a higher vapor pressure than would occur during sintering of pure said first sinterable material and

(ii) a second material having a higher affinity for said contaminant than does said first sinterable material, wherein the amount of the second material relative to the contaminant is from 95% of stoichiometric equivalent to 1000% stoichiometric excess; and

(b) heating said mixture at a temperature and for a time sufficient to allow said second material to at least partly mitigate the propensity of said contaminant to raise the vapor pressure during said sintering of said first sinterable material.

2. A process according to claim 1 , wherein said second material reacts with said contaminant to prevent said contaminant from forming a gas at the sintering temperature of said sinterable material.

3. A process according to claim 2 , wherein when said second material reacts with said contaminant it forms a fluid at a temperature below the sintering temperature of said first sinterable material, said fluid being sufficiently volatile to be eliminated from said sinterable material before said first sinterable material reaches said sintering temperature.

4. A process according to claim 1 , wherein said sinterable material when sintered forms a ceramic.

5. A process according to claim 1 , wherein said sinterable material is anon-oxide.

6. A process according to claim 5 , wherein said sinterable material is chosen from SiC, TiC, ZrC, BN, AlN, Si 3 N 4 , TiB 2 , ZrB 2 , HfB 2 , HfC, TiN and B 4 C and mixtures thereof.

7. A process according to claim 5 or 6 , wherein said contaminant is oxygen.

8. A process according to any of claims 5 - 6 , wherein said second material is selected from the group consisting of alkali metals and alkaline earth metals and salts thereof.

9. A process according to claim 8 , wherein said second material is an alkaline earth metal or a salt thereof.

10. A process according to any of claims 1 - 6 , wherein said contaminant is chlorine or fluorine.

11. A process according to any of claims 1 - 4 , wherein said first sinterable material is an oxide.

12. A process according to claim 11 , wherein said first sinterable material is chosen from K 2 O, Na 2 O, Li 2 O, ZnO, BeO, Cu 2 O, Fe 2 O 3 , SiO 2 , UO 2 , Bi 2 O 3 , CoO, Mn 3 O 4 , TiO 2 , MgO, ZrO 2 , BaO, ThO 2 , Ta 2 O 5 , Al 2 O 3 , Nb 2 O 5 , CaO, NiO, SrO, Cr 2 O 3 , V 2 O 5 , B 2 O 3 , HfO 2 , Y 2 O 3 , Mn 3 O 4 , BaTiO 3 , MgAl 2 O 4 , Y 3 Al 5 O 12 , Fe 3 O 4 and mixtures thereof.

13. A process according to claim 12 , wherein said first sinterable material is chosen from K 2 O, Na 2 O, Li 2 O, ZnO, BeO, Cu 2 O, Fe 2 O 3 , SiO 2 , UO 2 , Bi 2 O 3 , CoO, Mn 3 O 4 , TiO 2 , MgO, ZrO 2 , BaO, ThO 2 , Ta 2 O 5 , Al 2 O 3 , Nb 2 O 5 , CaO, NiO, SrO, Cr 2 O 3 , V 2 O 5 , B 2 O 3 , HfO 2 , Y 2 O 3 and mixtures thereof, and said contaminant is chlorine.

14. A process according to claim 12 , wherein said first sinterable material is chosen from K 2 O, Na 2 O, B 2 O 3 , Al 2 O 3 , Li 2 O, BeO, Cu 2 O, Fe 2 O 3 , SiO 2 , UO 2 , Bi 2 O 3 , CoO, NiO, TiO 2 , MgO, ZrO 2 , BaO, ThO 2 , Ta 2 O 5 , Nb 2 O 5 , CaO, SrO, Cr 2 O 3 , V 2 O 5 , Y 2 O 3 and mixtures thereof, and said contaminant is fluorine.

15. A process according to any of claims 1 - 6 , wherein said second material is an alkali metal or an alkali metal salt.

16. A process according to claim 15 , wherein said second material is a lithium material.

17. A process according to claim 15 , wherein said first sinterable material is an oxide and said lithium material is chosen from the group consisting of lithium metal, lithium salts and lithium-containing compounds in which the non-lithium component will be eliminated from the lithium material at a temperature below 1000° C.

18. A process according to claim 17 , wherein said lithium material is chosen from the group consisting of lithium oxide, lithium peroxide, lithium oxalate, lithium carbonate, lithium carbide, lithium nitride, lithium tert-butoxide, lithium tartrate, lithium stearate, and combinations thereof.

19. A process according to claim 15 , wherein said first material is a non-oxide and said lithium material is provided in the form of lithium metal.

20. A process according to claim 19 , wherein:

(a) said first sinterable material is a boride and said lithium material is provided in the form of lithium boride;

(b) said first sinterable material is a carbide and said lithium material is provided in the form of lithium carbide; or

(c) said first sinterable material is a nitride and said lithium material is provided in the form of lithium nitride.

21. A process according to claim 15 , wherein the molar ratio of alkali metal or alkali metal salt to contaminant is from about 1:1 to about 1.2:1.

22. A process according to claim 15 , wherein the amount of alkali metal or alkali metal salt relative to said contaminant is from 95% of stoichiometric equivalent to 100% stoichiometric excess.

23. A process according to claim 15 , wherein the amount of alkali metal or alkali metal salt relative to said contaminant is from a stoichiometric equivalent to 20% stoichiometric excess.

24. A process according to claim 15 , wherein the amount of alkali metal or alkali metal salt relative to said contaminant is from a 20% stoichiometric excess to a 1000% stoichiometric excess.

25. A process according to claim 15 , wherein the amount of alkali metal or alkali metal salt relative to said contaminant is from a 20% stoichiometric excess to a 100% stoichiometric excess.

26. A process according to claim 1 , wherein said temperature is below the sintering temperature of said sinterable material.

27. A process according to claim 26 , wherein said temperature is from 400-1100 degrees Celsius.

28. A process according to claim 27 , wherein said temperature is from 650-1100 degrees Celsius.

29. A process according to claim 27 , wherein said temperature is from 650-800 degrees Celsius.

30. A process for improving the uniformity of density in a sintered material, the process comprising:

(a) providing a mixture of

(i) a first sinterable material containing a contaminant the presence of which results in non-uniform density in said first sinterable material during sintering of said first sinterable material;

(ii) a second material having a higher affinity for said contaminant than does said first sinterable material, wherein the amount of the second material relative to the contaminant is from 95% of stoichiometric equivalent to 1000% stoichiometric excess;

(b) heating said mixture at a first temperature below the sintering temperature of said first sinterable material and for a first time sufficient to allow said second material to at least partly mitigate the propensity of the presence of said contaminant to result in non-uniform density during said sintering of said first sinterable material.

31. A process according to claim 30 , comprising (c) further heating said mixture for a second time and at a second temperature higher than said first temperature sufficient to sinter said first sinterable material.

32. A process according to claim 31 , wherein said mixture is not cooled between steps (b) and (c).

33. A process according to claim 31 , wherein said mixture is allowed to cool between steps (b) and (c).